Avensis T22 (7A-FE) - Cannot reach redline (in 2nd gear)

[AdamTheAvensisOwner]

Hello guys!
 

My Toyota Avensis T22 7A-FE with a 5MT transmission is currently having trouble reaching the rev limiter. The car drives fine overall, without any noticeable issues. This year, I did some major maintenance since it’s now 25 years old. Earlier this year, I replaced the suspension with KYB Excel-G, got new winter tires, changed the spark plugs (Denso Iridium, using the same model as the original), and swapped out the fuel filter. Just a few days ago, I also had the clutch replaced at a local garage.

However, after the clutch replacement, I noticed that in second and third gear, I can no longer reach 6,000 RPM (the redline on the tachometer). It revs smoothly up to nearly 5,000 RPM, but then I have to press the gas pedal all the way down to increase the RPMs further, and even then, it still won’t reach 6,000 RPM. Interestingly, when in neutral or even in first gear, I can rev up to 6,300 RPM, as expected.

I had the car connected to diagnostics at the same garage, but no issues were found. Also note: the car has been running completely fine before the clutch job.

Anyways, I'm definitely not a race driver, but I’d like my car to operate as it should (even if it’s getting a bit old 😄). Could this issue be related to the clutch change somehow? Or possibly the spark plug distributor?

 

Have a nice day!

 

[Konrad C]

I would say the old engine is protecting itself. 😂 

On a serious note, since the engine is old, there area lot of factors that could be causing the lack of top end revs. There could be a vacuum leak, or something was disturbed during the clutch change. I owned a '98 1.8 Leanburn hatchback years back, and very rarely up to 5000 rpm, let alone 6000 rpm. Most of the time I stayed within the torque band from 1500 to 4000 rpm. Peak torgue is stated 155nm (114 ft-lbs) at 2800 rpm. peak power is 108 hp at 5600 rpm. 

I would look at the breather system, the intake and also make sure the catalytic convertor is okay and not collapsed or restricted!  
I would have love to have kept my old Mk1 Avensis but times have moved on. I drive Mk3 Valvematic 1.8 Tourer which has higher power and torque figures at higher rpm. Now that can rev, but again I hardly need to go even near 4000rpm.